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OM-413 184 558K February 2001 Processes Stick (SMAW) Welding TIG (GTAW) Welding Description Engine Driven Welding Generator Miller LeGend NT Visit our website at www.MillerWelds.com From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will Miller is the first welding help you figure out what the problem is. The equipment manufacturer in parts list will then help you to decide which the U.S.A. to be registered to the ISO 9001 Quality System exact part you may need to fix the problem. Standard. Warranty and service information for your particular model are also provided. Working as hard as you do – every power source from Miller is backed by the most hassle-free warranty in the business. Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. TABLE OF CONTENTS WARNING This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The following terms are used interchangeably throughout this manual: TIG = GTAW Stick = SMAW SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . 1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Selecting Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Optional Remote 14 Receptacle RC1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 – OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 – OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. 100 Hz Auxiliary Power Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. 60 Hz Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Wiring Optional 240 Volt Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. Changing Engine Oil, Oil Filter, And Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7. Servicing Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 – AUXILIARY POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 – STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 1 1 1 2 3 4 4 5 5 5 6 7 8 8 9 9 9 10 10 11 11 12 12 12 13 14 14 15 15 16 16 17 17 18 18 19 20 21 21 22 23 23 24 25 26 29 30 37 46 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. ELECTRIC SHOCK can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. Do not touch live electrical parts. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal. SIGNIFICANT DC VOLTAGE exists after stopping engine on inverters. Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts. ARC RAYS can burn eyes and skin. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit. Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Always verify the supply ground – check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When making input connections, attach proper grounding conductor first – double-check connections. Frequently inspect input power cord for damage or bare wiring – replace cord immediately if damaged – bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. If ventilation is poor, use an approved air-supplied respirator. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. OM-413 Page 1 WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. Protect yourself and others from flying sparks and hot metal. Do not weld where flying sparks can strike flammable material. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. HOT PARTS can cause severe burns. Allow cooling period before maintaining. Wear protective gloves and clothing when working on a hot engine. Do not touch hot engine parts or just-welded parts bare-handed. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. Wear approved ear protection if noise level is high. Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. MAGNETIC FIELDS can affect pacemakers. Pacemaker wearers keep away. Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations. CYLINDERS can explode if damaged. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs. FLYING METAL can injure eyes. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. Wear approved safety glasses with side shields even under your welding helmet. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder – explosion will result. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards. 1-3. Engine Hazards FUEL can cause fire or explosion. Stop engine and let it cool off before checking or adding fuel. Do not add fuel while smoking or if unit is near any sparks or open flames. Do not overfill tank – allow room for fuel to expand. Do not spill fuel. If fuel is spilled, clean up before starting engine. Dispose of rags in a fireproof container. OM-413 Page 2 STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold to avoid scalding. Always check coolant level at overflow tank, if present on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements. Wear safety glasses and gloves and put a rag over radiator cap. Turn cap slightly and let pressure escape slowly before completely removing cap. MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary. To prevent accidental starting during servicing, disconnect negative (–) battery cable from battery. Keep hands, hair, loose clothing, and tools away from moving parts. Reinstall panels or guards and close doors when servicing is finished and before starting engine. Before working on generator, remove spark plugs or injectors to keep engine from kicking back or starting. Block flywheel so that it will not turn while working on generator components. BATTERY ACID can BURN SKIN and EYES. Do not tip battery. Replace damaged battery. Flush eyes and skin immediately with water. ENGINE EXHAUST GASES can kill. Use equipment outside in open, well-ventilated areas. If used in a closed area, vent engine exhaust outside and away from any building air intakes. ENGINE HEAT can cause fire. BATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, and protective clothing when working on a battery. Stop engine before disconnecting or connecting battery cables or servicing battery. Do not allow tools to cause sparks when working on a battery. Do not use welder to charge batteries or jump start vehicles. Observe correct polarity (+ and –) on batteries. Disconnect negative (–) cable first and connect it last. Do not locate unit on, over, or near combustible surfaces or flammables. Keep exhaust and exhaust pipes way from flammables. EXHAUST SPARKS can cause fire. Do not let engine exhaust sparks cause fire. Use approved engine exhaust spark arrestor in required areas – see applicable codes. 1-4. Additional Symbols For Installation, Operation, And Maintenance FALLING UNIT can cause injury. Use lifting eye to lift unit only, NOT running gear, gas cylinders, trailer, or any other accessories. Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. OVERUSE can cause OVERHEATING. Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit. STATIC (ESD) can damage PC boards. FLYING SPARKS can cause injury. Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. Sparks can cause fires — keep flammables away. Put on grounded wrist strap BEFORE handling boards or parts. Use proper static-proof bags and boxes to store, move, or ship PC boards. TILTING OF TRAILER can cause injury. Use tongue jack or blocks to support weight. Properly install welding generator onto trailer according to instructions supplied with trailer. OVERHEATING can damage motors. Turn off or unplug equipment before starting or stopping engine. Do not let low voltage and frequency caused by low engine speed damage electric motors. Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable. READ INSTRUCTIONS. Use only genuine MILLER replacement parts. Perform engine maintenance and service according to this manual and the engine manual. OM-413 Page 3 H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. ARC WELDING can cause interference. Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. 1-5. Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3. Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. 1-6. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields 1. Keep cables close together by twisting or taping them. Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. To reduce magnetic fields in the workplace, use the following procedures: 2. Arrange cables to one side and away from the operator. OM-413 Page 4 3. Do not coil or drape cables around your body. 4. Keep welding power source and cables as far away from operator as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended. SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 11/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Identifie un message de sécurité particulier. Signifie NOTA ; n’est pas relatif à la sécurité. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger. 1-2. Dangers relatifs au soudage à l’arc Les symboles présentés ci-après sont utilisés tout au long du présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-5. Veuillez lire et respecter toutes ces normes de sécurité. L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées. Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants. Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation. Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de toucher des composants. LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. UN CHOC ÉLECTRIQUE peut tuer. Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les circuits internes de l’appareil sont également sous tension à ce moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un danger. N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ les pièces endommagées. Entretenir l’appareil conformément à ce manuel. Porter un harnais de sécurité quand on travaille en hauteur. Maintenir solidement en place tous les panneaux et capots. Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure. Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Ne jamais toucher les pièces électriques sous tension. Porter des gants et des vêtements de protection secs ne comportant pas de trous. S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre. Ne pas se servir de source électrique àcourant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber. Se servir d’une source électrique àcourant électrique UNIQUEMENT si le procédé de soudage le demande. Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé. Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité). Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux. Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre. En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions. Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endommagé ou dénudé – remplacer le cordon immédiatement s’il est endommagé – un câble dénudé peut provoquer une électrocution. Mettre l’appareil hors tension quand on ne l’utilise pas. Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés. Ne pas enrouler les câbles autour du corps. Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct – ne pas utiliser le connecteur de pièce ou le câble de retour. Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine. Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). Porter des protections approuvés pour les oreilles si le niveau sondre est trop élevé. Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc. Porter des vêtements de protection constitué dans une matière durable, résistant au feu (laine ou cuir) et une protection des pieds. LES FUMÉES ET LES GAZ peuvent être dangereux. Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé. Eloigner votre tête des fumées. Ne pas respirer les fumées. À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air homologué. Lire les spécifications de sécurité des matériaux (MSDSs) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs. Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger. Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants. Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage. OM-413 Page 5 LE SOUDAGE peut provoquer un incendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger. Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier. Prévoir une période de refroidissement avant d’effectuer des travaux d’entretien. Porter des gants et des vêtements de protection pour travailler sur un moteur chaud. Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces récemment soudées. LE BRUIT peut affecter l’ouïe. Le bruit des processus et des équipements peut affecter l’ouïe. Fermer l’alimentation du gaz protecteur en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. Porter des protections approuvés pour les oreilles si le niveau sondre est trop élevé. LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques. Porteurs de stimulateur cardiaque, restez à distance. Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points. Si des BOUTEILLES sont endommagées, elles pourront exploser. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution. Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs. Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser. Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. Ne jamais placer une torche de soudage sur une bouteille à gaz. Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud. Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables. Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués. Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures. Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté. Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité). Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie. Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. En cas de non utilisation, enlever la baguette d’électrode du porte-électrode ou couper le fil à la pointe de contact. Porter des vêtements de protection dépourvus d’huile tels que des gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef. Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes. DES PARTICULES VOLANTES peuvent blesser les yeux. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. Ne jamais souder une bouteille pressurisée – risque d’explosion. Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état. Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille. Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille. Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publication P-1 CGA énumérées dans les normes de sécurité. 1-3. Dangers existant en relation avec le moteur LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion. LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des brûlures. Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein. Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue. Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son expansion. Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renversé avant de faire démarrer le moteur. Jeter les chiffons dans un récipient ignifuge. OM-413 Page 6 Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter de se brûler. Toujours vérifier le niveau de liquide de refroidissement dans le vase d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du moteur). Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant : Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. DES ORGANES MOBILES peuvent provoquer des blessures. L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et sur la PEAU. Ne pas approcher les mains des ventilateurs, courroies et autres pièces en mouvement. Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection. Arrêter le moteur avant d’installer ou brancher l’appareil. Demander seulement à un personnel qualifié d’enlever les dispositifs de sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de dépannage. Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, débrancher le câble négatif (–) de batterie de la borne. Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes mobiles. Remettre en place les panneaux ou les dipositifs de protection et fermer les portes à la fin des travaux d’entretien et avant de faire démarrer le moteur. Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise en route accidentelle du moteur. Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le générateur. L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie. Eviter de provoquer des étincelles avec les outils en travaillant sur la batterie. Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicules de démarrage rapide. Observer la polarité correcte (+ et –) sur les batteries. Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier lieu. Ne pas renverser la batterie. Remplacer une batterie endommagée. Rincer immédiatement les yeux et la peau à l’eau. LES GAZ D’ÈCHAPPEMENT DU MOTEUR peuvent provoquer des accidents mortels. Utiliser l’équipement à l’extérieur dans des zones ouvertes et bien ventilées. En cas d’utilisation dans un endroit fermé évacuer les gaz d’échappement du moteur vers l’extérieur à distance des entrées d’air dans les bâtiments. LA CHALEUR DU MOTEUR peut provoquer un incendie. Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. Tenir à distance les produits inflammables de l’échappement. LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie. Empêcher les étincelles d’échappement du moteur de provoquer un incendie. Utiliser uniquement un pare-étincelles approuvé – voir codes en vigueur. 1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance LA CHUTE DE L’APPAREIL peut blesser. Utiliser l’anneau de levage uniquement pour soulever l’appareil lui-même ; sans chariot, de bouteilles de gaz, remorque, ou autres accessoires. Utiliser un équipement de levage de capacité suffisante pour lever l’appareil. En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. LES ÉTINCELLES VOLANTES risquent de provoquer des blessures. Porter un écran facial pour protéger le visage et les yeux. Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps. Les étincelles risquent de causer un incendie – éloigner toute substance inflammable. L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT. LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes. UNE REMORQUE QUI BASCULE peut entraîner des blessures. LE SURCHAUFFEMENT peut endommager le moteur électrique. Laisser l’équipement refroidir ; respecter le facteur de marche nominal. Réduire le courant ou le facteur de marche avant de poursuivre le soudage. Ne pas obstruer les passages d’air du poste. Utiliser les supports de la remorque ou des blocs pour soutenir le poids. Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant. Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur. Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles. Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a lieu. LIRE LES INSTRUCTIONS. Utiliser seulement les pièces de rechange d’origine. Effecteur la maintenance et la mise en service d’après le manuel et celui du moteur. OM-413 Page 7 LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. LE SOUDAGE À L’ARC risque de provoquer des interférences. Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio–navigation et de communication, les services de sécurité et les ordinateurs. Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation. L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. Si le FCC signale des interférences, arrêter immédiatement l’appareil. Effectuer régulièrement le contrôle et l’entretien de l’installation. Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles. L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots. Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement. Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi. En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail. 1-5. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Règles de sécurité en soudage, coupage et procédés connexes, norme CSA W117.2, de l’Association canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3. Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme NFPA 51B, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. 1-6. Information sur les champs électromagnétiques Données sur le soudage électrique et sur les effets, pour l’organisme, des champs magnétiques basse fréquence Afin de réduire les champs électromagnétiques dans l’environnement de travail, respecter les consignes suivantes : 1 Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine”. Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage. OM-413 Page 8 2 3 4 5 Garder les câbles ensembles en les torsadant ou en les attachant avec du ruban adhésif. Mettre tous les câbles du côté opposé de l’opérateur. Ne pas courber pas et ne pas entourer pas les câbles autour de votre corps. Garder le poste de soudage et les câbles le plus loin possible de vous. Relier la pince de masse le plus près possible de la zone de soudure. Consignes relatives aux stimulateurs cardiaques : Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est alors recommandé de respecter les consignes ci–dessus. SECTION 2 – DEFINITIONS 2-1. Symbol Definitions h Fast/Slow (Run/Idle) Stop Engine Fast (Run) Start Engine Read Operator’s Manual Engine Oil Fuel Battery (Engine) Engine Engine Choke Check Valve Clearance Do not switch while welding Work Connection Positive Negative Alternating Current (AC) Output Welding Arc (Electrode) Protective Earth (Ground) Stick (SMAW) TIG (GTAW) Hours Seconds Time On Temperature Panel/Local Remote Unlocked Locked s Circuit Breaker A Amperes Slow (Idle) V Volts SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Welding Mode CC/AC CC/DC Weld Output Range 35 – 225 A 25 – 200 A Rated Welding Output 225 A, 25 V, 100% Duty Cycle 200 A, 25 V, 100% Duty Cycle Maximum OpenCircuit Voltage 80 72 Auxiliary Power Rating Single-Phase, 5 kVA/kW, 42/21 A, 120/240 V AC, 60 Hz And Single-Phase, 1 kVA/kW, 9 A, 115 V AC, 100 Hz Fuel Capacity Engine 10 gal (38 L) Tank Onan Performer P218 Air-Cooled, Two-Cylinder, Four-Cycle, 18 HP Gasoline Engine OM-413 Page 9 3-2. Dimensions, Weights, And Operating Angles Dimensions Height 33-1/2 in (851 mm) Width 18-3/4 in (476 mm) Depth 46 in (1164 mm) A 18 in (457 mm) B 16-1/2 in (419 mm) C 3/4 in (19 mm) D 3-1/8 in (79 mm) E 32-3/4 in (832 mm) F 45-1/2 in (1156 mm) G 13/32 in (10 mm) Dia. A B C Do not exceed tilt angles or engine could be damaged or unit could tip. D G 4 Holes Do not move or operate unit where it could tip. E 25° F 25° 25° 25° Weight Engine End 800 426 590 lb (267 kg) 3-3. Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. Continuous Welding 100% Duty Cycle at 225 Amperes CC/AC, 200 Amperes CC/DC SB-115 570 OM-413 Page 10 3-4. Volt-Ampere Curves A. For CC/AC Mode The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. B. For CC/DC Mode 185 621 / 185 622 3-5. Auxiliary Power Curve The auxiliary power curve shows the auxiliary power in amperes available at the receptacles. 185 623 OM-413 Page 11 3-6. Fuel Consumption 185 620 SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Movement Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. Airflow Clearance Do not lift unit from end. 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) OR Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. 1 2 3 18 in (460 mm) 18 in (460 mm) Grounding Location 4 3 1 GND/PE 2 Electrically bond generator frame to vehicle frame by metal-to-metal contact. Generator Base Metal Vehicle Frame Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire. 4 If unit does not have GFCI receptacles, use GFCIprotected extension cord. OR OR Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. 2 install1 10/00 – Ref. 800 652 / Ref. 800 477-A / 158 936-A / S-0854 OM-413 Page 12 4-2. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. 1 5 4 1 2 3 4 5 Eye Protection – Safety Glasses Or Face Shield Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to bottom of well (maximum). 3 Do not overfill battery cells. Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps. 6 Battery Charger Read and follow all instructions supplied with battery charger. 2 Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 amperes. Disconnect charging cables and install battery. When electrolyte is low, add only distilled water to cells to maintain proper level. 6 5 A For 30 Minutes Tools Needed: OR + – rubbergloves 30 A For 12 Minutes glasses drybatt1 1/98 – S-0886 OM-413 Page 13 4-3. Connecting The Battery Connect negative (–) cable last. – + Tools Needed: 3/8, 1/2 in Ref. 800 394-C / Ref. 203 096 / Ref. S-0756-D 4-4. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Full This unit has a low oil pressure shutdown switch. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the oil pressure shutdown system to monitor oil level. Full Gasoline Follow run-in procedure in engine manual. Fuel Add fresh fuel before starting engine the first time (see maintenance label for specifications). Fill fuel tank up to 1/2 in. (13 mm) from top to allow room for expansion. Check fuel level on a cold engine before use each day. Oil After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label). To improve starting: cold weather Keep battery in good condition. Store battery in warm area off concrete surface. Use correct grade oil for cold weather. Ref. 801 757-B / 800 395-B OM-413 Page 14 4-5. Installing Exhaust Pipe Engine backfire can cause severe burns or other injuries. Do not point exhaust pipe toward control panel. Keep away from exhaust outlet. Point exhaust pipe in desired direction but always away from front panel and direction of travel. Tools Needed: 1/2 in 801 681 / Ref. 203 096 4-6. Connecting To Weld Output Terminals Use only one set of terminals at a time. 1 2 3 4 1 AC Work Weld Output Terminal 2 AC Electrode Weld Output Terminal 3 DC Negative (–) Weld Output Terminal 4 DC Positive (+) Weld Output Terminal For Stick welding Direct Current Electrode Positive (DCEP), connect work cable to DC (–) terminal and electrode cable to DC (+) terminal. For Direct Current Electrode Negative (DCEN), reverse cable connections. For most DC TIG welding applications, connect work cable to DC (+) terminal and torch cable to DC (–) terminal. Tools Needed: 3/4 in Ref. 801 757-B / Ref. 203 096 OM-413 Page 15 4-7. Selecting Weld Cable Sizes Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft 400 ft (105 m) (120 m) Weld Output Terminals Turn off power before connecting to weld output terminals. Welding Amperes 10 – 60% Duty Cycle 60 – 100% Duty Cycle 100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60) 150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95) 200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120) 250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 2/0 (2x70) 300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) Do not use worn, damaged, undersized, or poorly spliced cables. 10 – 100% Duty Cycle * This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger cable. **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use S-0007-E– ***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505. 4-8. Optional Remote 14 Receptacle RC1 Information A B K J I H C L N D M G E F A *The remaining sockets are not used. 801 757-B OM-413 Page 16 Socket* Socket Information A Contact closure to B completes 15 volts dc contactor control circuit. B 15 volts dc. C +4.5 volts dc output to remote control. D Remote control circuit common. E 0 to +4.5 volts dc input command signal from remote control. K Chassis common. SECTION 5 – OPERATING WELDING GENERATOR 5-1. Front Panel Controls 5 6 1 7 3 2 4 Using Idle Lock Switch + + = = + OR = 1860 rpm (Power/Idle) No Load: 1860 rpm (Power/Idle) Load: 3000 rpm (Weld) 3000 rpm (Weld) Ref. 203 096 1 Engine Control Switch Use switch to start engine, select speed, and stop engine. In Run/Idle position, engine runs at power/idle rpm at no load, and weld rpm under weld or 100 Hz auxiliary power receptacle load. In Run position, engine runs at weld rpm. 2 Idle Lock Switch Use switch to lock engine at power/idle speed (see Table). In Unlock position, Engine Control switch and optional Remote Control switch determine engine speed. Optional Remote Control switch overrides Idle Lock. 3 Engine Choke Control 5 Coarse Adjust Switch Use control to change engine air-fuel mix. Do not switch under load. To Start: pull out choke and turn Engine Control switch to Start position. Release switch and slowly push choke in when engine starts. Use switch to select weld amperage range. If the engine does not start, let the engine come to a complete stop before attempting restart. To Stop: turn Engine Control switch to Off position. 4 Remote Control Switch (Optional) Use switch to select front panel or remote amperage control (see Section 4-8). For best arc starts, use lowest amperage range possible. 6 Fine Adjust Control Use control to select weld amperage within the range selected by the Coarse Adjust switch. Control may be adjusted while welding. Scale is for reference only. Weld output would be 88 A DC with control settings as shown (50% of 70 to 105 A). 7 Engine Hour Meter OM-413 Page 17 5-2. Remote Control (Optional) Weld output terminals are energized when Remote Control switch is in Panel/On position and engine is running. 1 Remote 14 Receptacle RC1 Connect optional remote control to RC1 (see Section 4-8). In Example: Range = 70 to 105 A DC Percentage of Range = 50% Min = 70 A DC Max = 88 A DC (50% of 70 to 105) 1 Max (88 A DC) Min (70 A DC) Set Switch Set Coarse Adjust Set Fine Adjust (%) Adjust Remote Control Ref. 801 757-B / Ref. 203 096 SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. 100 Hz Auxiliary Power Receptacle Do not operate 50/60 Hz or 60 Hz equipment from 100 Hz receptacle. 1 2 115 V 9 A 100 Hz AC Receptacle RC4 Receptacle supplies single-phase power at weld speed only. Total output available is 1 kVA/kW. 2 Circuit Breaker CB10 CB10 protects receptacle from overload. If CB10 opens, receptacle does not work. 1 Press button to reset circuit breaker. If breaker continues to open, contact a Factory Authorized Service Agent. Ref. 203 096 OM-413 Page 18 6-2. 60 Hz Auxiliary Power Receptacles If unit does not have GFCI receptacles, use GFCIprotected extension cord. 1 8 5 2 6 3 1 240 V 50 A Receptacle RC1 2 120 V 20 A AC Receptacle RC2 3 120 V 20 A AC Receptacle RC3 Receptacles supply 60 Hz singlephase power at power/idle speed only. Maximum output from RC1 is 5 kVA/kW. Maximum output from either RC2 or RC3 is 2.4 kVA/kW (CSA: 1.8 kVA/kW). For 60 Hz auxiliary power, set controls as shown in table. Weld output and 60 Hz auxiliary power output are not available at the same time. 4 120 V 15 A AC GFCI Receptacles GFCI2 and GFCI3 (Optional) If a ground fault is detected, the GFCI receptacle Reset button pops out and the circuit opens to disconnect the faulty equipment. Check for damaged tools, cords, plugs, etc. connected to the receptacle. Press button to reset receptacle and resume operation. At least once a month, run en- gine at power/idle speed and press Test button to verify GFCI is working properly. 7 5 Circuit Breaker CB3 6 Circuit Breaker CB4 CB3 protects RC2 and CB4 protects RC3 from overload. If CB3 or CB4 opens, the receptacle does not work. 7 For 60 Hz Auxiliary Power Only For 60 Hz Auxiliary Power OR Weld Output 4 Circuit Breaker CB1 CB1 protects all the 60 Hz receptacles from overload. If CB1 opens, RC1, RC2 and RC3 do not work. Press button or move lever to On position to reset circuit breaker. If breaker continues to open, contact a Factory Authorized Service Agent. 8 Total Auxiliary Power Output Combined output of receptacles limited to the 5 kVA/kW output of the generator: EXAMPLE: If 10 A is drawn from RC2, only 16 A is available at RC1: (120 V x 10 A) + (240 V x 16 A) = 5.0 kVA/kW Any Position PANEL PANEL ON ON Ref. 203 096 OM-413 Page 19 6-3. Wiring Optional 240 Volt Plug The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram. 1 3 7 1 4 Current Available in Amperes 240 V Receptacle* Each 120 V Duplex Receptacle 20 15 10 5 0 0 5 10 15 20 Plug Wired for 120/240 V, 3-Wire Load When wired for 120 V loads, each duplex receptacle shares a load with one half of 240 V receptacle. 120V 120V 5 240V 6 2 V x A = Watts *One 240 V load or two 120 V loads. 3 4 2 Plug Wired for 240 V, 2-Wire Load 3 Neutral (Silver) Terminal 4 Load 1 (Brass)Terminal 5 Load 2 (Brass) Terminal 6 Ground (Green) Terminal 7 Amperes Available using 120/240 V Plug 240V 6 5 Tools Needed: 120 813-D OM-413 Page 20 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. NOTE Stop engine before maintaining. Recycle engine fluids. See also Engine Manual and maintenance label. Service engine more often if used in severe conditions. * To be done by Factory Authorized Service Agent. 8h 20 h Check and clean spark arrestor screen. See Section 7-7. Check fluid levels. See Section 4-4. Wipe up spills. 25 h Service air filter wrapper (foam element).See Section 7-3. 50 h Clean and tighten weld terminals. Clean cooling system. See Engine Manual. 100 h Change oil. See Section 7-5 and maintenance label. Change oil filter. See Section 7-5 and maintenance label. Clean and tighten battery connections. Service air filter element. See Section 7-3. 200 h Check valve clearance.* Replace fuel filter. See Section 7-5. Check spark plugs. Replace unreadable labels. 500 h Service welding generator brushes and slip rings. Service more often in dirty conditions.* Repair or replace cracked cables. 1000 h Remove cylinder head deposits.* Clean crankcase breather valve. Blow out or vacuum inside. During heavy service, clean monthly OR OM-413 Page 21 7-2. Maintenance Label OM-413 Page 22 7-3. Servicing Air Cleaner Stop engine. 1 Do not run engine without air cleaner or with dirty element. 1 2 Wrapper (Foam Element) Wash wrapper with soap and water solution. Allow wrapper to air dry completely. Spread 1 tablespoon SAE 30 oil evenly into wrapper. Squeeze out excess oil. 2 Element Replace element if dirty, oily, or damaged. aircleaner3 1/97 – 156 852 / Ref. 203 096 / S-0759 7-4. Overload Protection Stop engine. Disconnect negative (–) battery cable. 1 1 2 Fuse F1 (See Parts List) F1 protects the exciter excitation winding from overload. If F1 opens, weld output stops. 2 Fuse F6 (See Parts List) F6 protects the engine throttle solenoid from overload. If F6 opens, the engine will not run at weld speed. Replace any open fuses. Reinstall cover before operating. When a fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. Tools Needed: 3/8 in Ref. 801 757-B / Ref. 203 096 OM-413 Page 23 7-5. Changing Engine Oil, Oil Filter, And Fuel Filter Stop engine and let cool. 1 Oil Drain Valve 2 1/2 ID x 12 in Hose 3 Oil Filter Change engine oil and filter according to engine owner’s manual. Close valve and valve cap before adding oil and running engine. Fill crankcase with new oil to full mark on dipstick (see Section 7-2). 4 Fuel Filter 5 Fuel Line Replace line if cracked or worn. Install new filter. Wipe up any spilled fuel. Full Start engine, and check for fuel leaks. Stop engine, tighten connections as necessary, and wipe up fuel. 4 5 3 2 1 Tools Needed: Ref. 801 757-B / 800 395-B / Ref. 203 096 / S-0842 OM-413 Page 24 7-6. Adjusting Engine Speed After tuning engine, check engine speeds with a tachometer. See table for proper no load speeds. If necessary, adjust speeds as follows: 1860 ± 50 rpm Remove cover. 3000 ± 50 rpm Start engine, and rotate Fine Adjust control to 10. 1 Carburetor 2 Throttle Solenoid Power/Idle Speed Adjustment 1 3 Power/Idle Speed Rod 4 Lock Nut 5 Adjustment Nut Loosen lock nut and rotate adjustment nut until engine runs at power/ idle speed. Tighten lock nut. Weld Speed Adjustment Place Engine Control switch in Run position. 9 5 6 Lock Nut Loosen nut. 7 Hex Swivel Rotate swivel until engine runs at weld speed. Tighten lock nut. 4 3 2 8 Weld Speed Governor Spring 9 Power/Idle Speed Governor Spring If a spring becomes loose or disconnected, reattach as shown. Stop engine. Reinstall cover. 6 8 7 Top View Tools Needed: 3/8, 5/16, 7/16 in Ref. 801 757-B OM-413 Page 25 7-7. Servicing Optional Spark Arrestor Stop engine and let cool. 1 Spark Arrestor Screen Clean and inspect screen. Replace spark arrestor if screen wires are broken or missing. 1 Tools Needed: 1/4 in Ref. 801 682-A / Ref. 203 096 7-8. Troubleshooting A. Welding Trouble No weld output. Remedy Check fuse F1 and replace if necessary (see Section 7-4). Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes and slip rings, integrated rectifier SR2, and voltage regulator board PC2. No or erratic weld output. Check control settings. Clean and tighten connections to electrode and workpiece. Use dry, properly-stored electrodes for Stick and TIG welding. Check internal and external connections to weld output terminals; check connections at stabilizer. Remove excessive coils from weld cables. Clean and tighten connections both inside and outside welding generator. Low or high weld output. Check control settings. Check and adjust engine speed (see Section 7-6). Lack of high frequency when TIG welding; difficulty in starting an arc. Use proper size tungsten. Check optional high frequency arc starting unit. Be sure that torch is not close to any grounded metal. Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace necessary parts. OM-413 Page 26 Trouble Wandering arc when TIG welding – poor control of arc direction. Remedy Reduce gas flow rate. Select proper size tungsten. Properly prepare tungsten. TIG tungsten electrode oxidizing and not remaining bright after weld. Shield weld zone from drafts. Increase postflow time. Check and tighten all gas fittings. Properly prepare tungsten. Repair torch parts if water has leaked into torch. B. 60 Hz Auxiliary Power Trouble No auxiliary power output. Remedy Reset circuit breakers (see Section 6-2). Check Engine Control and Idle Lock switch settings. 60 Hz auxiliary power available only at power/idle speed (see table in Section 5-1). Check receptacle(s) for continuity and proper connections. Replace receptacle(s) if necessary. Check fuse F1 and replace if necessary (see Section 7-4). Have Factory Authorized Service Agent check brushes and slip rings, control relay CR2, integrated rectifier SR2, and idle module. Low auxiliary power output. Check and adjust engine speed (see Section 7-6). Check fuse F1 and replace if necessary (see Section 7-4). Have Factory Authorized Service Agent check brushes and slip rings, integrated rectifier SR2, control relay CR3, and voltage regulator board PC2. High auxiliary power output. Check and adjust engine speed (see Section 7-6). Have Factory Authorized Service Agent check voltage regulator board PC2. C. 100 Hz Auxiliary Power Trouble No auxiliary power output. Remedy Reset circuit breaker CB10 (see Section 6-1). Check receptacle RC4 for continuity and proper connections. Replace receptacle if necessary. Check fuse F1 and replace if necessary (see Section 7-4). Have Factory Authorized Service Agent check brushes and slip rings, and integrated rectifier SR2. Low auxiliary power output. Run engine at weld speed (see Sections 5-1 and 6-1). D. Engine Trouble Engine will not crank. Remedy Check battery voltage. Check battery connections and tighten if necessary. Check plug PLG5 and plug PLG8 connections. Have Factory Authorized Service Agent check Engine Control switch S1. OM-413 Page 27 Trouble Engine will not start. Remedy Check fuel level. Check battery voltage. Check battery connections and tighten if necessary. Check oil level (see Section 4-4). Check low oil pressure shutdown switch (see engine manual). Check plug PLG5 and plug PLG8 connections. Engine starts, but stops when Engine Check oil level (see Section 4-4). Control switch returns to Run position. Check and refill crankcase with proper viscosity oil for operating temperature, if necessary. Check low oil pressure shutdown switch (see engine manual). Check plug PLG5 and plug PLG8 connections. Engine stopped during normal operation. Check fuel level. Check oil level (see Section 4-4). Check low oil pressure shutdown switch (see engine manual). Periodically recharge battery (approximately every 3 months). Replace battery. Check voltage regulator and connections according to engine manual. Engine idles, but does not run at weld speed. Move Idle/Lock switch to Unlock position. Check fuse F6, and replace if open (see Section 7-4). Have Factory Authorized Service Agent check Engine Control switch, idle module PC1, throttle solenoid TS1, control relay CR1, and current transformer CT1. Engine does not return to idle speed. Remove weld and auxiliary power loads. Move Engine Control switch to Run/Idle position. Check throttle linkage for smooth, non-binding operation. Have Factory Authorized Service Agent check Engine Control switch, idle module PC1, throttle solenoid TS1, control relay CR1, and current transformer CT1. Unstable or sluggish engine speeds. Readjust throttle linkage if necessary. Check throttle solenoid TS1 for smooth operation. Tune-up engine according to engine manual. Battery discharges between uses. Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water. Periodically recharge battery (approximately every 3 months). Replace battery. Check voltage regulator and connections according to engine manual. OM-413 Page 28 SECTION 8 – ELECTRICAL DIAGRAM 203 098 Figure 8-1. Circuit Diagram For Welding Generator OM-413 Page 29 SECTION 9 – AUXILIARY POWER GUIDELINES 9-1. Selecting Equipment 1 2 3 Auxiliary Power Receptacles – Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment 1 2 3 Be sure equipment has this symbol and/or wording. OR aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577 9-2. Grounding Generator To Truck Or Trailer Frame 1 2 3 4 Generator Base Metal Vehicle Frame Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire. If unit does not have GFCI receptacles, use GFCI-protected extension cord. 3 1 4 GND/PE OR 2 2 Electrically bond generator frame to vehicle frame by metal-to-metal contact. S-0854 OM-413 Page 30 9-3. Grounding When Supplying Building Systems 1 1 2 2 GND/PE Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. Use ground device as stated in electrical codes. 2 3 ST-800 576-B 9-4. How Much Power Does Equipment Require? 1 3 2 1 VOLTS 115 AMPS 4.5 Hz 60 Resistive Load A light bulb is a resistive load and requires a constant amount of power. 2 Non-Resistive Load Equipment with a motor is a non-resistive load and requires approximately six times more power while starting the motor than when running (see Section 9-8). 3 3 Rating Data Rating shows volts and amperes, or watts required to run equipment. AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. 4.5 A x 115 V = 520 W The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load. (200 W + 200 W + 200 W) + 520 W = 1120 W The total load applied by the three flood lamps and drill is 1120 watts. S-0623 OM-413 Page 31 9-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty Rating Starting Watts Running Watts 1/8 HP 1/6 HP 1/4 HP 1/3 HP 1/2 HP 1/3 HP 1/2 HP 3/4 HP 1 HP 1-1/2 HP 2 HP 3 HP 5 HP 1-1/2 HP 5 HP 7-1/2 HP 10 HP 1/8 HP 1/6 HP 1/4 HP 1/3 HP 1/2 HP 800 1225 1600 2100 3175 2020 3075 4500 6100 8200 10550 15900 23300 8100 23300 35000 46700 1000 1400 1850 2400 3500 300 500 600 700 875 720 975 1400 1600 2200 2850 3900 6800 2000 6000 8000 10700 400 550 650 800 1100 9-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std. (e.g. Conveyors, Feed Augers, Air Compressors) High Torque (e.g. Barn Cleaners, Silo Unloaders, Silo Hoists, Bunk Feeders) 3-1/2 cu. ft. Mixer High Pressure 1.8 Gal/Min Washer 2 gal/min 2 gal/min Refrigerator or Freezer Shallow Well Pump Sump Pump OM-413 Page 32 Rating 1/4 HP 1/2 HP 3/4 HP 2 HP 1/3 HP 1/2 HP 3/4 HP 1 HP 1-1/2 HP 2 HP 3 HP 5 HP 1-1/2 HP 5 HP 7-1/2 HP 10 HP 1/2 HP 500 PSI 550 PSI 700 PSI 1/3 HP 1/2 HP 1/3 HP 1/2 HP Starting Watts Running Watts 1000 1650 3400 4400 2900 10500 1720 2575 4500 6100 8200 10550 15900 23300 8100 23300 35000 46700 3300 3150 4500 6100 3100 2150 3100 2100 3200 1000 650 1000 1400 1100 2800 720 975 1400 1600 2200 2850 3900 6800 2000 6000 8000 10700 1000 950 1400 1600 800 750 1000 800 1050 9-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet & Dry Vac Rating Starting Watts Running Watts 1/4 in 3/8 in 1/2 in 6-1/2 in 7-1/4 in 8-1/4 in 9 in 10 in 14 in 6 in 8 in 10 in 1/2 HP 1 HP 1-1/2 HP 2 HP 1-1/2 HP, 12 in 2 HP, 14 in Standard 9 in Heavy Duty 12 in 1/3 HP 18 in HID Metal Halide Mercury Sodium Vapor 400 gph 900 gph 3/4 HP, 16 in 1 HP, 20 in 1/2 HP 3/4 HP 1 HP 1/4 HP 1.7 HP 2-1/2 HP 350 400 600 500 900 1400 4500 6300 2500 1720 3900 5200 3000 6000 8200 10500 1100 1100 350 500 2100 400 125 313 1000 1400 1250 600 900 4500 6100 3150 4500 6100 1900 900 1300 350 400 600 500 900 1400 1500 1800 1100 720 1400 1600 1000 1500 2200 2800 1100 1100 350 500 700 400 100 250 1000 200 500 1400 1600 950 1400 1600 700 900 1300 OM-413 Page 33 9-8. Power Required To Start Motor 4 1 3 AC MOTOR VOLTS 230 AMPS 2.5 CODE M Hz 60 HP 1/4 PHASE 1 1 2 3 4 2 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage. Step 2: Find Motor HP and Volts. Step 3: Determine starting amperage (see example). Welding generator amperage output must be at least twice the motor’s running amperage. Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0 kVA/HP x HP x 1000 VOLTS = STARTING AMPERAGE EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2 11.2 x 1/4 x 1000 = 12.2 A Starting the motor requires 12.2 amperes. 230 S-0624 9-9. How Much Power Can Generator Supply? 1 Limit Load To 90% Of Generator Output Always start non-resistive (motor) loads in order from largest to smallest, and add resistive loads last. 2 1 2 5 Second Rule If motor does not start within 5 seconds, turn off power to prevent motor damage. Motor requires more power than generator can supply. Ref. ST-800 396-A / S-0625 OM-413 Page 34 9-10. Typical Connections To Supply Standby Power 1 2 3 Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection. Customer-supplied equipment is required if generator is to supply standby power during emergencies or power outages. 4 1 240 V 120/240 Volt 60 Hz Three-Wire Service Circuit Breakers or Fused Disconnect Switch Obtain and install correct circuit breakers or switch. 5 120 V 6 Neutral 2 Extension Cord Select as shown in Section 9-11. 120 V 3 Generator Connections Connect terminals or plug of adequate amperage capacity to cord. Follow all applicable codes and safety practices. Turn off or unplug all equipment connected to generator before starting or stopping engine. When starting or stopping, the engine has low speed which causes low voltage and frequency. 240 V 120 V Load Power Company Service Meter Main and Branch Overcurrent Protection Double-Pole, Double-Throw Transfer Switch 120 V 7 Load Connections 4 7 CB or Item 4 is not necessary if circuit protection is already present in welding generator auxiliary power output circuit. F1 5 6 240 V 120/240 Volt Single-Phase Three-Wire Generator Output Connection 120 V 120 V Ground S-0405-A OM-413 Page 35 9-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) Load (Watts) 5 600 7 840 10 1200 15 4 6 8 10 12 14 350 (106) 225 (68) 137 (42) 100 (30) 400 (122) 250 (76) 150 (46) 100 (30) 62 (19) 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15) 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9) 20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9) 25 3000 175 (53) 112 (34) 62 (19) 37 (11) 30 3600 150 (46) 87 (26) 50 (15) 37 (11) 35 4200 125 (38) 75 (23) 50 (15) 40 4800 112 (34) 62 (19) 37 (11) 45 5400 100 (30) 62 (19) 50 6000 87 (26) 50 (15) *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) Load (Watts) 5 1200 7 1680 10 2400 15 4 8 10 12 14 700 (213) 450 (137) 225 (84) 200 (61) 800 (244) 500 (152) 300 (91) 200 (61) 125 (38) 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31) 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18) 20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18) 25 6000 350 (107) 225 (69) 125 (38) 75 (23) 30 7000 300 (91) 175 (53) 100 (31) 75 (23) 35 8400 250 (76) 150 (46) 100 (31) 40 9600 225 (69) 125 (38) 75 (23) 45 10,800 200 (61) 125 (38) 50 12,000 175 (53) 100 (31) *Conductor size is based on maximum 2% voltage drop OM-413 Page 36 6 SECTION 10 – STICK WELDING (SMAW) GUIDELINES 10-1. Stick Welding Procedure Weld current starts when electrode touches workpiece. Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. 1 5 2 3 4 2 Work Clamp Electrode A small diameter electrode requires less current than a large one. Follow electrode manufacturer’s instructions when setting weld amperage (see Section 10-2). 3 6 1 Workpiece Make sure workpiece is clean before welding. 7 4 5 6 Insulated Electrode Holder Electrode Holder Position Arc Length Arc length is the distance from the electrode to the workpiece. A short arc with correct amperage will give a sharp, crackling sound. 7 Slag Use a chipping hammer and wire brush to remove slag. Remove slag and check weld bead before making another weld pass. Tools Needed: stick 12/96 – ST-151 593 OM-413 Page 37 7014 7018 7024 Ni-Cl 308L ALL DEEP EP ALL DEEP 6013 EP,EN ALL LOW GENERAL 7014 EP,EN ALL MED 7018 EP ALL LOW SMOOTH, EASY, FAST LOW HYDROGEN, STRONG 7024 EP,EN NI-CL EP FLAT HORIZ FILLET ALL 308L EP ALL USAGE PENETRATION EP 6011 AC 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 DC* 450 400 350 300 AMPERAGE RANGE 250 200 150 POSITION 6013 6010 ELECTRODE 6010 & 6011 100 50 DIAMETER ELECTRODE 10-2. Electrode and Amperage Selection Chart MIN. PREP, ROUGH HIGH SPATTER LOW SMOOTH, EASY, FASTER LOW CAST IRON LOW STAINLESS *EP = ELECTRODE POSITIVE (REVERSE POLARITY) EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY) Ref. S-087 985-A 10-3. Striking an Arc – Scratch Start Technique 1 1 2 3 Electrode Workpiece Arc Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it. 2 3 S-0049 10-4. Striking an Arc – Tapping Technique 1 1 2 3 2 Electrode Workpiece Arc Bring electrode straight down to workpiece; then lift slightly to start arc. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it. 3 S-0050 OM-413 Page 38 10-5. Positioning Electrode Holder 10°-30° 90° 90° End View of Work Angle Side View of Electrode Angle GROOVE WELDS 10°-30° 45° 45° End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 10-6. Poor Weld Bead Characteristics 1 2 3 4 5 Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration 1 2 4 3 5 S-0053-A 10-7. Good Weld Bead Characteristics 1 2 3 Fine Spatter Uniform Bead Moderate Crater During Welding Weld a new bead or layer for each 1/8 in. (3.2 mm) thickness in metals being welded. 4 5 1 2 3 4 No Overlap Good Penetration into Base Metal 5 S-0052-B OM-413 Page 39 10-8. Conditions That Affect Weld Bead Shape NOTE Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Angle Too Small Correct Angle 10° - 30° Angle Too Large Drag ELECTRODE ANGLE Spatter Normal Too Short Too Long ARC LENGTH Normal Slow Fast TRAVEL SPEED S-0061 10-9. Electrode Movement During Welding NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better. 1 2 1 2 3 Stringer Bead – Steady Movement Along Seam Weave Bead – Side to Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of electrode. 3 S-0054-A OM-413 Page 40 10-10.Butt Joints 1 1 2 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position before final weld. 2 Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. 3 1/16 in (1.6 mm) 30° Single V-Groove Weld Good for materials 3/16 – 3/4 in (5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels. 4 3 Create 30 degree angle of bevel on materials in V-groove welding. 4 Double V-Groove Weld Good for materials thicker than 3/16 in (5 mm). S-0662 10-11.Lap Joint 30° Or Less 30° Or Less 1 1 1 2 Move electrode in circular motion. 3 Single-Layer Fillet Weld Multi-Layer Fillet Weld Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass. Weld both sides of joint for maximum strength. 3 2 Electrode Single-Layer Fillet Weld Multi-Layer Fillet Weld S-0063 / S-0064 10-12.Tee Joint 1 2 Keep arc short and move at definite rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface. 1 2 45° Or Less Electrode Fillet Weld For maximum strength weld both sides of upright section. 2 3 Multi-Layer Deposits Weld a second layer when a heavier fillet is needed. Use any of the weaving patterns shown in Section 10-9. Remove slag before making another weld pass. 1 3 S-0060 / S-0058-A / S-0061 OM-413 Page 41 10-13.Weld Test 1 2 3 3 Strike weld joint in direction shown. A good weld bends over but does not break. 3 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) Vise Weld Joint Hammer 2 To 3 in (51-76 mm) 2 2 1 1 S-0057-B 10-14.Troubleshooting – Porosity Porosity – small cavities or holes resulting from gas pockets in weld metal. Possible Causes Corrective Actions Arc length too long. Reduce arc length. Damp electrode. Use dry electrode. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding. 10-15.Troubleshooting – Excessive Spatter Excessive Spatter – scattering of molten metal particles that cool to solid form near weld bead. Possible Causes Corrective Actions Amperage too high for electrode. Decrease amperage or select larger electrode. Arc length too long or voltage too high. Reduce arc length or voltage. OM-413 Page 42 10-16.Troubleshooting – Incomplete Fusion Incomplete Fusion – failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding. Adjust work angle or widen groove to access bottom during welding. Momentarily hold arc on groove side walls when using weaving technique. Keep arc on leading edge of weld puddle. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding. 10-17.Troubleshooting – Lack Of Penetration Lack Of Penetration – shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle. Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Reduce travel speed. 10-18.Troubleshooting – Excessive Penetration Excessive Penetration – weld metal melting through base metal and hanging underneath weld. Excessive Penetration Possible Causes Excessive heat input. Good Penetration Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. OM-413 Page 43 10-19.Troubleshooting – Burn-Through Burn-Through – weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Excessive heat input. Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 10-20.Troubleshooting – Waviness Of Bead Waviness Of Bead – weld metal that is not parallel and does not cover joint formed by base metal. Possible Causes Unsteady hand. Corrective Actions Use two hands. Practice technique. 10-21.Troubleshooting – Distortion Distortion – contraction of weld metal during welding that forces base metal to move. Base metal moves in the direction of the weld bead. Possible Causes Excessive heat input. Corrective Actions Use restraint (clamp) to hold base metal in position. Make tack welds along joint before starting welding operation. Select lower amperage for electrode. Increase travel speed. Weld in small segments and allow cooling between welds. OM-413 Page 44 Notes OM-413 Page 45 SECTION 11 – PARTS LIST Hardware is common and not available unless listed. Figure 11-1. Main Assembly OM-413 Page 46 ST-801 812-E Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-1. Main Assembly . . 1 . . . . . . . . . . . . . . . . . 181 881 . . 2 . . . . . . . . . . . . . . . . . 147 601 . . 3 . . . . . . . . . . . . . . . . . 108 487 . . 4 . . . . . . . . . . . . . . . . . 183 433 . . 5 . . . . . . . . . . . . . . . . +183 221 . . 5 . . . . . . . . . . . . . . . . ♦185 354 . . 6 . . . . . . . . . . . . . . . . . 182 365 . . 6 . . . . . . . . . . . . . . . . ♦185 351 . . 7 . . . . . . . . . . . . . . . . . 183 626 . . . . . . . . . . . . . . . . . . . . . . 185 323 . . 8 . . . . . . . . . . . . . . Figure 11-3 . . 9 . . . . . . . . . . . . . . . . . 186 670 . . 10 . . . . . . . . . . . . . . . . 181 789 . . 11 . . . . . . . . . . . . . . . . 165 271 . . 12 . . . . . . . . . . . . . . . . 176 891 . . 13 . . . . . . . . . . . . . . . . 183 314 . . 14 . . . . . . . . . . . . . . . +184 600 . . 15 . . . . . . . . . . . . . . . . 183 434 . . 16 . . . . . . . . . . . . . . . . 065 313 . . 17 . . . . TS1 . . . . . . 186 308 . . 18 . . . . . . . . . . . . . . . . 185 182 . . 19 . . . . . . . . . . . . . . . . 192 796 . . 20 . . . . . . . . . . . . . . . . 064 646 . . 21 . . . . . . . . . . . . . . . . 128 533 . . 22 . . . . . . . . . . . . . . . . 128 431 . . . . . . . . . . . F6 . . . . . . . *192 395 . . . . . . . . . . . . . . . . . . . . . . 192 868 . . . . . . . . . . . . . . . . . . . . . ♦192 093 . . 23 . . . . . . . . . . . . . Figure 11-4 . . 24 . . . . . . . . . . . . . . . . 167 731 . . 25 . . . . . . . . . . . . . . . . 182 935 . . 26 . . . . . . . . . . . . . . . . 168 385 . . 27 . . . . . . . . . . . . . . . . 182 897 . . 28 . . . . . . . . . . . . . . . . 167 730 . . . . . . . . . . . . . . . . . . . . . . 165 600 . . 29 . . . . . . . . . . . . . . . . 168 037 . . 30 . . . . . . . . . . . . . . . . 182 845 . . 31 . . . . . . . . . . . . . . . . 197 930 . . 32 . . . . . . . . . . . . . . . . 181 057 . . 33 . . . . DC-Z . . . . . . 184 313 . . 34 . . . . . . . . . . . . . . . . 183 980 . . 35 . . . . . . . . . . . . . . . . 164 920 . . 36 . . . . AC-Z . . . . . . 184 312 . . 37 . . . . . . . . . . . . . . . . 182 928 . . 38 . . . . . . . . . . . . . . . . 159 905 . . 39 . . . . . . . . . . . . . . . . 186 667 . . 40 . . . . . . . . . . . . . . . . 121 652 . . 41 . . . . . . . . . . . . . . . . 174 001 . . 42 . . . . SR1 . . . . . . 142 503 . . 43 . . . . . . . . . . . . . . . . 180 628 . . 44 . . . . . . . . . . . . . Figure 11-2 . . 45 . . . . CT1 . . . . . . 184 486 . . 46 . . . . . . . . . . . . . . . . 182 079 . . . . . . . . . . . . . . . . . . . . . . 178 632 . . . . . . . . . . . . . . . . . . . . . . 124 253 . . . . . . . . . . . . . . . . . . . . . . 182 922 . . . . . . . . . . . . . . . . . . . . . . 182 925 . . GROMMET, plastic fill neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAP, tank w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIPE, exhaust elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, top stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, rear upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, rear upper stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAFFLE, engine air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAL BAFFLE, engine air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, w/components w/harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UPRIGHT BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAL, barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE, oil drain 3/8NPT (Included w/engine) . . . . . . . . . . . . . . . . . . . . . . . LABEL, engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE, gas electric start (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUFFLER, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKET, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SOLENOID, 12VDC 46A (includes solenoid control module) . . . . . . . . . . BRACKET, mtg solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE KIT, solenoid control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPRING, high speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LINK, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWIVEL, inline .250-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE, mintr gl slo-blo 10A 32 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDICATOR/CAP ASSEMBLY (Dipstick) . . . . . . . . . . . . . . . . . . . . . . . . . PUMP, electric fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE, bat pos 19.500 No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLDDOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning battery explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DOOR, access battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE, bat neg 29.00 No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE, bat neg 18.500 6ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY, stor 12V 430 crk dry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAN, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg stab/reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, rear lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FILTER KIT, fuel w/clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAL, fuel hose fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECTIFIER, si 1PH 300A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, lower front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TANK, fuel (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FITTING, stand pipe hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, fuel tank 1.210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GAUGE, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 OM-413 Page 47 Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-1. Main Assembly (Continued) . . 47 . . . . . . . . . . . . . . . . 182 367 . . 47 . . . . . . . . . . . . . . . ♦185 352 . . 48 . . . . . . . . . . . . . . . . 182 366 . . 48 . . . . . . . . . . . . . . . ♦185 353 . . 49 . . . . . . . . . . . . . . . . 182 761 . . 50 . . . . . . . . . . . . . . . . 192 042 . . . . . . . . . . PLG8 . . . . . . 177 859 . . . . . . . . . . PLG5 . . . . . . 116 045 . . . . . . . . . . PLG1 . . . . . . 168 071 .. .. .. .. .. .. .. .. .. PANEL, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, side RH stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, side RH stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning engine fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, body 5 terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 1 ♦OPTIONAL +When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. 5 4 6 3 Hardware is common and 2 not available unless listed. 7 1 8 9 29 11 28 10 27 26 25 15 20 21 14 13 12 22 19 18 17 30 23 16 24 ST-801 813-E Figure 11-2. Front Panel w/Components OM-413 Page 48 Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-2. Front Panel w/Components (Figure 11-1 Item 43) . . 1 . . . . . CB10 . . . . . . 083 432 . . .. 2 ............................ . . 3 . . . . . . . . . . . . . . . . . 188 313 . . . . 4 . . . . . . . . . . . . . . . . . 186 058 . . . . 5 . . . . . . S4 . . . . . . . 162 673 . . . . 6 . . . . . . R1 . . . . . . . 081 712 . . . . 7 . . . . . . S3 . . . . . . . . 011 611 . . . . . . . . . . . . . . . . . . . . . . . . 021 385 . . . . 8 . . . . . . S1 . . . . . . . 176 606 . . . . 9 . . . . RC2,3 . . . . . 141 432 . . . . 9 . . . . GFCI2,3 . . . ♦147 939 . . . . 10 . . . . CB1 . . . . . . 203 095 . . . . 11 . . . . CB3,4 . . . . . 093 996 . . . . 11 . . . . CB3,4 . . . . ♦093 995 . . . . 12 . . . . . HM . . . . . . . 145 247 . . . . 13 . . . . . . . . . . . . . . . . 199 031 . . . . 14 . . . . . . . . . . . . . . . . 119 014 . . . . 15 . . . R3,VR1 . . . . . 046 819 . . . . 16 . . . . . . . . . . . . . . . . 039 047 . . . . 17 . . . . . . . . . . . . . . . . 039 046 . . . . 18 . . . . PC4 . . . . . . 148 021 . . . . 19 . . . . . . . . . . . . . . . . 073 756 . . . . 20 . . . . . . . . . . . . . . . . 083 030 . . . . 21 . . . . . . . . . . . . . . . . 010 915 . . . . 22 . . . . . . . . . . . . . . . . 601 836 . . . . 23 . . . . . . . . . . . . . . . . 099 255 . . . . 24 . . . . . . . . . . . . . . . . 159 921 . . . . 25 . . . . . . . . . . . . . . . . 188 039 . . . . 26 . . . . RC1 . . . . . . 182 954 . . . . . . . . . . . . . . . . . . . . . . . . 119 172 . . . . 27 . . . . RC4 . . . . . . 188 263 . . . . 28 . . . . . . . . . . . . . . . . 148 956 . . . . 29 . . . . . . . . . . . . . . . . 097 924 . . . . 30 . . . . . . . . . . . . . . . . 203 016 . . CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH, selector 7 pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RHEOSTAT, WW 100W 30 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH, ignition 4 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECEPTACLE, str dx grd 2P3W 20A 125VAC . . . . . . . . . . . . . . . . . . . . RECEPTACLE, str dx grd 2P3W 15A 125VAC . . . . . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 2p 25a 240vac screw–90 . . . . . . . . . CIRCUIT BREAKER, 1P 20A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL, push/pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STAND-OFF, 6-32 x .625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, .250-20 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL, pwr output neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECEPTACLE, str 3P4W 50A 125/250VAC . . . . . . . . . . . . . . . . . . . . . . PLUG, str 50A 125/250V RECEPTACLE, 3P3W 15A 125V hinged . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOT, circuit breaker 2 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 1 2 2 1 2 2 1 1 1 1 1 1 1 2 1 3 3 2 1 1 1 1 1 1 1 ♦OPTIONAL +When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-413 Page 49 Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-3. Bracket w/Components (Figure 11-1 Item 8) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1 . . . . . . . . . . . . . . . . . 173 734 2 . . . . . . 1T . . . . . . . 172 661 3 . . . . . . . . . . . . . . . . . 172 731 4 . . . . . . F1 . . . . . . . *083 596 5 . . . . . SR2 . . . . . . 035 704 6 . . . . . . T1 . . . . . . . 184 417 7 . . . . . D2,3 . . . . . . 135 184 8 . . . . . R2,4 . . . . . . 008 951 9 . . . . . PC2 . . . . . . 160 888 10 . . . . . . . . . . . . . . . . 176 478 11 . . . . . . . . . . . . . . . . 184 420 12 . . . . CR3 . . . . . . 044 588 13 . . . . CR1 . . . . . . 173 069 14 . . . . CR2 . . . . . . 113 247 15 . . . . PC1 . . . . . . 186 224 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLOCK, stud connection 6P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLDER, fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE, mintr 12A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIODE BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, WW adj 180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSEMBLY, voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . STAND-OFF, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 12VDC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 12VDC SPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 12VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODULE, pull to weld/power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hardware is common and 4 not available unless listed. 5 2 1 1 1 1 1 2 2 1 4 1 1 1 1 1 6 3 2 1 7 8 PC2 9 15 14 10 13 12 11 7 ST-801 814-A Figure 11-3. Bracket w/Components *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-413 Page 50 Item No. Part No. Description Quantity Figure 11-4. Generator (Figure 11-1 Item 22) . . 1 . . . . . . . . . . . . . . . . . 182 092 . . 2 . . . . . . . . . . . . . . . . +184 363 . . 3 . . . . . . . . . . . . . . . . . 153 297 . . 4 . . . . . . . . . . . . . . . . . 143 220 . . 5 . . . . . . . . . . . . . . . . . 183 981 . . 6 . . . . . . . . . . . . . . . . . 107 313 . . 7 . . . . . . . . . . . . . . . . . 008 917 . . 8 . . . . . . . . . . . . . . . . . 134 981 . . 9 . . . . . . . . . . . . . . . . . 017 702 . . 10 . . . . . . . . . . . . . . . . 049 286 . . 11 . . . . . . . . . . . . . . . . 017 624 . . 12 . . . . . . . . . . . . . . . . 053 390 . . 13 . . . . . . . . . . . . . . . . 024 617 . . . . . . . . . . . . . . . . . . . . . . 602 348 . . 14 . . . . . . . . . . . . . . . . 007 250 . . 15 . . . . . . . . . . . . . . . . 047 878 . . 16 . . . . . . . . . . . . . . . . 161 306 . . 17 . . . . . . . . . . . . . . . . *126 984 . . 18 . . . . . . . . . . . . . . . . 005 614 . . . . . . . . . . PLG6 . . . . . . 130 204 . . . . . . . . . . RC6 . . . . . . 168 165 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHROUD, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENDBELL, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STATOR, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat stl .343 ID x 2.250 OD x .187thk . . . . . . . . . . . . . . . . . . . . . ADAPTER, fan rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADAPTER, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROTOR ASSEMBLY, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEARING, ball rdl sgl row 1.37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KEY, stl .250 x .250 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAR, retaining brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAP, brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRUSH w/SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 3 1 1 9 Hardware is common and not available unless listed. 8 7 6 11 5 3 12 10 13 4 1 2 14 18 17 16 15 ST-801 818 Figure 11-4. Generator +When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-413 Page 51 Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way. * LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor. 1. 5 Years Parts – 3 Years Labor * * 2. 3 Years — Parts and Labor * * * * * * 3. Original main power rectifiers Inverters (input and output rectifiers only) Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Semi-Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) 1 Year — Parts and Labor * * * * * * * * * * * * * * * * * DS-2 Wire Feeder Motor Driven Guns (w/exception of Spoolmate 185 & Spoolmate 250) Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Units Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment Running Gear/Trailers Plasma Cutting Torches (except APT & SAF Models) Field Options (NOTE: Field options are covered under True Blue for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.) 4. 6 Months — Batteries 5. 90 Days — Parts * * MIG Guns/TIG Torches Induction Heating Coils and Blankets * * * * * APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate 185 & Spoolmate 250 Canvas Covers Miller’s True Blue Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. 2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any. 3. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment. MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province. miller_warr 7/00 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA Replacement Parts Training (Schools, Videos, Books) International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 Technical Manuals (Servicing Information and Parts) Circuit Diagrams European Headquarters – United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066 Welding Process Handbooks www.MillerWelds.com Contact the Delivering Carrier for: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 2001 Miller Electric Mfg. Co. 1/01
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